Method of and apparatus for manufacturing imitation marble



Fdm 12, 1929. 1,701,619

ca. E. KENDALL METHOD OF AND APPARATUS FOR MANUFACTURING IMITATION MARBLE Filed Nov. 50, 1927 I INVENTUR 660?6 f. flaw 0 3%, u (gag/Z Z LQw/ I ATTORNEYS Patented Feb. 12, 1929.

, UNITED" STATES 1,701,619 PATENT OFFICE.

GEORGE KENDALL, OF KALAMAZOO, MICHIGAN.

METHOD OF AND APPARATUS FOR MANUFAGIUBING IMITA'IION MARBLE.

Application filed November 80, 1927. Serial No. 288,884.

This invention relates to improved apparatus and method for manufacture of concrete-slabs or blocks.

1 The objects of the invention are: 5 First, to provide an apparatus comprlsing molds in which such concrete, slabs or blocks can be effectively treated with an excess of moisture when in contact with a polished or smooth surface to produce polished effect on the slab.

Second, to provide an improved method and means of securing a smooth, hard, dense surface on concrete or cement devices.

Third, to provide an apparatus in which excess moisture can be introduced and effectively maintained in mass production.

Objects pertaining to details and economies of my invention will definitely appear from the descri tion to follow.

I accomplishthe o jects of my invention by the devices and means described n the following specification. The invention 15 clearly defined and pointed out in the claims. 7

A device embodying my invention is clearly illustrated in the accompanying drawing forming a part of this specification, in

which:

Fig. 1 is a detail perspective view of one of thesupporting moistening processing trays with a series of molds supported in the form thereinfpart of the molds being omitted.

Fig. 2 is an enlarged detail sectional view through the tray and the molds on a plane corresponding to line 22 of Fig. 1,

the superposed relation of trays being indicated by dotted lines.

Fig. 3 is a detail perspective view of one of the molds of pyroxylin or xanthate or or other flexible material, showing how the trays open out at the corners to permit ready separation and removal of the contents of the mold. 1

Fig. 4 is a detail perspective view' of a finishedsmall block or slab as it is removed from the mold.

Fig. 5 is a detail sectional View similar to Fig. 2 showing a single mold filling the entire form ofthe processing tray.

The parts will be identified by their numerals of reference which are the same in all the views.

1 is a processingtray having a central mold'supporting form 2 with a projecting ledge 3 forming a trough 4 for water to maintain moisture. This processing tra is preferably made of very orous absor ent concretewhich readily fi s and saturates with moisture. Other absorbent material might be used.

' The trays are adapted to be superimposed one from the other. The top edge of the tray 15 a broad plane surface and the bottom of the tray is a flat plane and entirely encloses the supporting form for the molds. Thetwater of capillarity tends to close the 30m 5 are the molds preferably -made of squares of pyroxylin, xanthate or other thin flexible polished or smooth material. The corners are cut out and the sides creased and folded up to form a complete mold with the corners merely closed together.

The mold, after the contents is hardened, is

very readily separated therefrom by deflecting the sides, which are sufiiciently flexible, making it possible to practically peel the mold from the molded concrete slab or block therein.

Where small blocks are desired a series of these molds 5 are placed side by side so that each supports the other as seen in Fig. 1. Where a large slab-is required the mold may entirely fill the form in the processing tray. It would be possible to line this tray with a metal foil or with light tin that could be flexed and opened out. However,

- celluloid or xanthate are especially good because of their very smooth surfaces and their lightness and flexibility. Celluloid can be used repeatedly. Xanthate is inexpensive and needs to be used only once.

In carrying out the process of manufacture, I place the molds in the form on the processing trays with their sides closed as indicated in Fig. 1, or supported by the form where a large mold is used. I then mix the cement or concrete very rich and very wet, applying it very thoroughly over the bottom of these molds. I then add less rich material also very wet and fill the upper parts with comparatively coarse material.

It may be even as coarse as grout, although a less coarse material than grout is desirable for most uses.

The processing trays are then laced one above the other as indicated in Fig. 2, the surrounding troughs 4 are filled with water and as the processing trays are porous and very absorbent, and fit'closely together, they surround the moldsivith a complete moist en-velope which is readily maintained b simply has ing the troughs 4 filled witi water which is done by turnmg a hose on the stack of trays. The joint between trays is practically water sealed.

The processing trays with their contained molds are allowed to stand for a long time to keep the contents completely moist in an excess of moisture and to permit the same to fully harden, and this moisture is so efl'ecti vely maintained that there is a film or layer of moisture between the blocks or slabs and the molds which enables the molds to be readil removed. This efiectively avoids the use 0 any other lubricant than the water. After the full hardening has taken lace, the blocks are removed and the moisture then dries off leaving substantially polished surface Without the use of anything other than the excess moisture to insure a separation of the blocks from the mold.

Portland cement or other similar hydraulie cement is used for the blocks. Colored designs can be imposed upon the same by introducing splotches or lines of colored material in the first or rich material layer in the bottoms of the molds.

It will therefore be observed that I have here an eflective apparatus and process for the production of such blocks or slabs. The structures can be considerably varied without departin from the invention which I desire to claim specifically in its preferred form and broadly as pointed out in the appended apparatus and process claims.

This invention is a development and in some respects an improvement of the invention described in my pending patent applicationfor patent filed March 5, 1926, Serial No. 92,636.

Having thus described my invention what I claim as new and desire to secure by Letters Patent is:

1. In an apparatus for making concrete blocks or slabs, the combination of a processing trap of porous absorbent, concrete material with a depressed mold supporting form and with projecting ledges forming a surrounding trough in the top thereof, and molds of smooth material with cut corners and flexible sides and bottom adapted to be placed within and substantially fill the said supporting form and adapted to receive wet concrete material and maintain the same in moist condition during the hardening process.

2. In an apparatus for making concrete blocks or slabs the combination of a proeessing tray of porous absorbent material,

with a depressed mold supporting form and with projecting ledges forming a surrounding trough in the to thereof, and molds of smooth material with cut corners and flexible sides and bottom adapted to be placed within and substantially fill the said supporting form and adapted to receive wet concrete material and maintain the same in moist condition during the hardening process.

3. In an apparatus for making concrete blocks or slabs, the combination of a processing tray of porous absorbent material,

with a depressed mold supporting form and with projecting ledges forming a surrounding trough in the top thereof, and molds adapted to be placed within the said supporting form and adapted to receive wet concrete material and maintain the same in moist condition during the hardening process.

4. In an apparatus for making concrete blocks or slabs, the combination of a processing tray of porous absorbent material with a depressed mold supporting form in the top thereof, and molds adapted to be placed within the said supporting form and adapted to receive wet concrete material and maintain the same in moist condition during the hardening process.

5. A mold for forming concrete blocks or slabs of smooth polished flexible material with open corners adapted to be readily opened and peeled off from the hardened concrete slab or block when formed, and means for maintaining moisture around the said mold.

6. The process of forming polished blocks or slabs consisting in forming a very rich wet mixture in contact with a somewhat flexible smooth surface, imposing designs thereon of different colored material, and enclosing and maintaining the same in the presence of an excess-amount of moisture until fully hardened.

7. The process of forming polished blocks or slabs consisting in forming a very rich wet mixture in contact with a somewhat flexible smooth surface, and enclosing and maintaining the same in the presence of an excgss amount of moisture until fully hardene 8. In an apparatus for making concrete blocks or slabs, the combination of a processing tray of porous absorbent material with'a depressed mold supporting form and with projecting ledges forming a surrounding trough in the top thereof, and molds formed of sheets of "pyroxylin with flexible sides and ends opening at the corners, adapted to be placed within the said supporting form and adapted to receive wet concrete material and maintain the same in moist condition during the hardening procqss.

* 9. In an apparatus for making concrete blocks or slabs, the combination of a processing tray of porous absorbent material with a depressed mold supporting form in block when formed, and means for maintaining moisture around the said mold.

11. A mold for forming concrete blocks or slabs of sheet xanthate with open corners 15 adapted to be readily opened and peeled off from the hardened concrete slab or block when formed, and means for maintaining moisture around the said mold.

In witness whereof I have hereunto set 20 m hand.

y GEORGE E. KENDALL. 

